CosmoPod

Single-dose beauty capsules / Source: Shutterstock

AfricaAsiaBeautyCosmoPodDissolvableEuropeFlexibleLeak ProofLightweightNorth AmericaOdour ResistantPackagingSealableSeaweedSouth AmericaTemperature-Resistant

WHAT WE SAY:

The beauty industry has a waste problem, and it’s not just the packaging. It’s estimated that between 20% and 40% of all beauty products never get used – unsold, expired or sat on bathroom shelves for eternity. That’s a lot of costly formula simply being thrown away.

Single-dose beauty, however, is turning the tide with pre-measured portions remaining stable far longer than the average bottled product. But portion packaging is a concern, and we’re backing encapsulation as a plastic-free alternative. Catalent’s CosmoPods are an ideal solution for single-dose beauty without the waste – but could their reach expand far beyond the world of skincare and hair care?

CosmoPod

WHAT IS COSMOPOD?

Created by Catalent’s Consumer Health division, CosmoPods are individualised, single-dose capsules that can be used for skincare, bath and body, hair care, fragrance and colour cosmetics. They feature a twist-off top for ease of use and are made from carrageenan, a natural plant-based Seaweed extract.
Available globally, Catalent claims that the odourless pods are biodegradable and in compliance with cGMP, FDA and EMA regulations. When dry, the pods break down in a similar way to vegetable peel, only quicker, and in water they dissolve altogether. The brand says that nothing is left behind, including a residue or harmful chemicals.
The individual capsules are hermetically sealed and formulas are anhydrous with no added preservatives. The company claims that one pod remains viable and fresh for up to 30 months.
Pods protect the formula from air and light, improving the stability of the product when compared to traditional dosage forms such as sachets. A resistance to higher humidity and temperature also ensures optimal freshness.
The company launched CosmoPod Duo in 2021, a combined dual formula, single-serving capsule that allows for two formulas or ingredients to mix and activate at the point of use. This design is especially pertinent for highly active ingredients that aren’t compatible together over long periods of time.

KEY PROPERTIES:

Dissolvable
Flexible
Leak Proof
Lightweight
Odour Resistant
Sealable
Temperature-Resistant

INDUSTRY:

Beauty
Packaging

AVAILABILITY:

Commercially Available

DIVE DEEPER:

CosmoPods don’t just tackle the issue of product waste, but plastic packaging waste too. Plastic packaging for beauty products is a systemic problem, with over 383 million units of personal care packaging manufactured every day, most of which either can't or won't be recycled.
CosmoPods remove the need for primary plastic packaging, with each single-dose capsule in a self-contained pod, and they don’t require protective plastic packaging to extend their shelf life either.
Catalent offers a range of pre-packaged formulas in the CosmoPod packaging solution, including skincare ingredients retinol, vitamin C and vitamin E; serums for sensitive, oily or tired skin; and hair care such as silicones, argan oils and shea butter.
The water-free formulas, combined with the lightweight nature of the plant-based capsules, reduces potential transit emission burdens.
In 2020, Catalent expanded its Consumer Health manufacturing facilities with a USD 3.2 million investment in Strathroy, Canada, and Sorocaba, Brazil. The new sites manufacture the CosmoPod and Vegicaps Capsules.

Single-dose beauty capsules / Source: Shutterstock

Catalent CosmoPod Duo / Source: Catalent

KEY FACTS:

20-40%

of all beauty products never get used – unsold, expired or sat on bathroom shelves for eternity

383mn

units of personal care packaging are manufactured every day, most of which either can’t or won’t be recycled

$3.2mn

In 2020, Catalent expanded its Consumer Health manufacturing facilities with a USD 3.2 million investment in Canada and Brazil

Key Questions to Ask:

What secondary packaging should you use?

CosmoPods are designed as primary packaging for beauty formulations, however, they would typically be sold in batches. Consider how the CosmoPods can be packaged in a way which retains the environmental credentials of the original pod – consider Moulded Fibre versus a plastic tub.

Will accessibility reduce consumer reach?

The use of a CosmoPod requires a certain level of dexterity, so consider how the ability of your users could make the product unsuitable for them. Those without stable use of both hands could struggle to twist and apply the product. Unlike a standard bottled cream, it is not feasible to apply a CosmoPod with one hand.

Will scaling this solution lead to unforeseen issues?

While the waterless nature of CosmoPods reduces the weight of each individual capsule, their size and format means a much larger packaging volume is required to house the same quantity of product packaged in one bottle. Consider how a larger packaging volume can have an environmental impact.

Does it go back to the soil as a nutrient?

What does the biodegradability claim really mean? The stated biodegradability, while in compliance with cGMP, FDA and EMA regulations, is not quantified with a time and it is unknown how the capsules will react in the open environment. It would also be necessary to establish if the packaged formula affects the degradability or the effects on the soil.

What else could it encapsulate?

While this solution is most prominent in the health and beauty sector, it has the potential to move into the food and drinks industry too. Could you be the first to bring a capsule drink or snack to the market? Catalent offers a range of edible capsule forms too.

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